Apparatus and method for assembling, testing, labeling, inspecting and packaging a low profile magnetic component

ABSTRACT

An apparatus for manufacturing a low profile magnetic component, a method of manufacturing an apparatus for manufacturing low profile magnetic components, and a method of manufacturing a low profile magnetic component. In one embodiment, the apparatus includes a frame with a fixture adapted to hold a magnetic core. The apparatus includes a loading station coupled to the frame that is adapted to load the magnetic core onto the fixture. Also coupled to the frame is a wire feeding and cutting station configured to feed and cut a wire and form a conductive element having a particular configuration. The wire feeding and cutting station also positions the conductive element for mounting on the magnetic core. The embodiment includes a clamping station coupled to the frame for clamping and mounting the conductive element on the magnetic core.

TECHNICAL FIELD OF THE INVENTION

[0001] The present invention is directed, in general, to a manufacturing apparatus and, more specifically, to an automated apparatus to be used for the assembly, testing, labeling, inspection and packaging of a low profile magnetic component.

BACKGROUND OF THE INVENTION

[0002] Magnetic devices, such as inductors and transformers, are employed in many different types of electrical devices, including communications equipment and power supplies. In practice, most magnetic devices are fabricated of one or more windings formed as an elongated electrical conductor, such as a wire of circular or rectangular cross-section or a planar electrical conductor wound about or mounted to a bobbin composed of a dielectric material, such as plastic. In some instances, the electrical member is soldered to terminations on the bobbin. Alternatively, the electrical member may be threaded through the bobbin for connection directly to an underlying circuit board. In some cases, a magnetic core is disposed about the bobbin to impart a greater reactance to the magnetic device and thereby alter its operating characteristics. The use of a bobbin, however, generally results in a magnetic device with a large profile, which not only takes up valuable space on the circuit board, but also results in a height that is unacceptable for use in the low profile compact systems that customers demand.

[0003] In addition to bobbins, magnetic devices are also formed using a magnetic core, such as ferrite or iron, that is wound with one or more conductive coils. These devices are generally referred to as “wire-wound core devices.” It has been particularly difficult to miniaturize such devices, unlike most other electronic components, such as resistors, diodes, capacitors and transistors, which have been drastically reduced in size.

[0004] One low profile magnetic device is described in U.S. Pat. No. 5,574,420, entitled LOW PROFILE SURFACE MOUNTED MAGNETIC DEVICES AND COMPONENTS THEREFOR, Roy, Apurba, et al. (Roy), commonly assigned with the invention described herein. The device described in Roy is a magnetic component formed by a plurality of conductive elements surrounding a small magnetic core. The conductive elements pass through holes or channels in the magnetic core with each end of the conductive element bent outwards to allow for a surface mount connection to a printed wiring board.

[0005] In order to overcome certain perceived deficiencies in the Roy device, including the fact that the device described in Roy may be difficult to manufacture because of the shape of the magnetic core and arrangement of conductive elements about the core, another device was developed. This device is described in U.S. patent application Ser. No. 09/552,811, entitled LOW PROFILE SURFACE MOUNTED MAGNETIC DEVICES, Catalano, Robert, J., et. al. (Catalano), also commonly assigned with the present invention. The Catalano device is also a low profile magnetic component formed by a plurality of conductive elements surrounding a small magnetic core. In Catalano, however, the ends of the conductive elements located in recesses about the magnetic core are bent inward against the bottom of the core, instead of passing through holes or channels in the core and bending outward. The inwardly bent ends of the conductive elements form coplanar and surface mountable contact surfaces. The magnetic components described in Catalano can be formed into a magnetic device, such as an inductor, by placing two or more such devices in close proximity and using conductive traces on a printed wiring board or other insulated substrate to complete the windings. The magnetic device can then be utilized in a power supply such as, for example, an inductor in an output filter or, in groups of two or more, as transformers.

[0006] Although the device described in Catalano has a number of applications, the problem remains of how best to manufacture the device. The small size of the device makes it difficult to assemble manually. While a number of prior art tools exist to perform certain manufacturing functions necessary to complete the device, generally such prior art tools must be separately operated. This separate operation generally requires manual manipulation by an operator, which makes the manufacturing process very slow and quite expensive.

[0007] Accordingly, what is needed in the art is an apparatus for manufacturing a low profile magnetic component, a method of manufacturing such an apparatus, and a method of manufacturing a low profile magnetic component.

SUMMARY OF THE INVENTION

[0008] To address the above-discussed deficiencies of the prior art, the present invention provides for an apparatus for manufacturing a low profile magnetic component, a method of manufacturing an apparatus for manufacturing low profile magnetic components, and a method of manufacturing a low profile magnetic component. In one embodiment, the apparatus includes a frame with a fixture that is adapted to hold a magnetic core. The apparatus includes a loading station coupled to the frame that is adapted to load the magnetic core onto the fixture. Also coupled to the frame is a wire feeding and cutting station configured to feed and cut a wire and form a conductive element having a particular configuration. The wire feeding and cutting station also positions the conductive element for mounting on the magnetic core. The embodiment includes a clamping station coupled to the frame for clamping and mounting the conductive element on the magnetic core.

[0009] The present invention introduces, in broad scope, an apparatus for handling materials in order to produce a finished low profile magnetic component. In a particularly useful embodiment, the apparatus can be automated so that, when set up and adjusted, it can be started and left running with a minimum of monitoring or human intervention. This represents a distinct advantage over prior art devices used to manufacture low profile magnetic components, which prior art devices generally included one or more steps or functions required to be performed manually.

[0010] In one embodiment, the apparatus includes a first video inspection station to inspect the magnetic component for conformity with certain specifications, such as proper placement of the conductive element. In still another embodiment, the apparatus includes an electrical test station for testing certain electrical characteristics of the magnetic component. In either of these embodiments, if a magnetic component is defective because of improper assembly or a failure to fulfil required electrical parameters, such defective component can be rejected before being packaged. If the apparatus consistently produces defective components, an operator can be alerted to perform the necessary troubleshooting functions and restore the apparatus to normal operation.

[0011] A particularly useful embodiment of the apparatus has a labeling station coupled to the frame adapted to print and place a label on the magnetic component. In one embodiment, the apparatus includes a second video inspection station to inspect the label for conformity with predetermined specifications, such as correct printing and proper placement of the label on the body of the magnetic component.

[0012] It still another embodiment, the apparatus includes a packaging station coupled to the frame to remove the magnetic component from the fixture and place it into a package for shipment or delivery to the end user. One aspect of this embodiment provides for the loading station to be configured to remove magnetic cores from a receiving package and the packaging station configured to package completed magnetic components in a shipping package identical to the receiving package. This permits the reuse of receiving packaging material as shipping packaging material. The recycling of packaging material in this manner results in a significant cost savings.

[0013] The invention also provides for several embodiments of methods to manufacture low profile magnetic devices and methods to manufacture an apparatus for manufacturing low profile magnetic devices. These embodiments will be described herein in more detail.

[0014] The foregoing has outlined, rather broadly, preferred and alternative features of the present invention so that those skilled in the art may better understand the detailed description of the invention that follows. Additional features of the invention will be described hereinafter that form the subject of the claims of the invention. Those skilled in the art should appreciate that they can readily use the disclosed conception and specific embodiment as a basis for designing or modifying other structures for carrying out the same purposes of the present invention. Those skilled in the art should also realize that such equivalent constructions do not depart from the spirit and scope of the invention in its broadest form.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] For a more complete understanding of the present invention, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:

[0016]FIG. 1A illustrates an isometric view of a prior art embodiment of a low profile magnetic component;

[0017]FIG. 1B illustrates a cross sectional view of the prior art magnetic component illustrated in FIG. 1A;

[0018]FIG. 2A illustrates an isometric view of the frame of an embodiment of an apparatus for manufacturing a low profile magnetic component and a series of fixtures adapted to hold magnetic cores;

[0019]FIG. 2B, illustrates an isometric view of an embodiment of a fixture configured to hold a magnetic core;

[0020]FIG. 2C illustrates an isometric view of the frame with an embodiment of a loading station coupled thereto;

[0021]FIG. 2D illustrates an isometric view of the frame with embodiments of a wire feeding and cutting station and a clamping station coupled thereto;

[0022]FIG. 2E illustrates an isometric view of the frame with an embodiment of the final clamping and fixture alignment station coupled thereto:

[0023]FIG. 2F illustrates an isometric view of an embodiment of an electrical test station;

[0024]FIG. 2G illustrates an isometric view of the frame with embodiments of a labeling station and packaging station coupled thereto; and

[0025]FIG. 3 illustrates one embodiment of a method of manufacturing a magnetic component using a magnetic component manufacturing apparatus.

DETAILED DESCRIPTION

[0026] Referring initially to FIG. 1A, illustrated is a prior art isometric view of an embodiment of a low profile magnetic component 100 of the type described in U.S. patent application Ser. No. 09/552,811, entitled LOW PROFILE SURFACE MOUNTED MAGNETIC DEVICES, Catalano, Robert, J., et. al., commonly assigned with the invention and incorporated herein by this reference. This prior art magnetic component 100 is illustrated in order to more clearly understand the description of the invention that follows. The actual size of the component 100, however is much smaller than it appears in FIG. 1A. In one embodiment, for example, the component 100 is approximately three-sixteenths of an inch wide, three-eights of an inch long and less than three-thirty seconds of an inch high. The present invention is thus directed to an apparatus and method for manufacturing a very small magnetic component 100, the size of which requires careful and special handling.

[0027] Turning to FIG. 1B, illustrated is a cross sectional view of the prior art magnetic component 100 illustrated in FIG. 1A. The component 100 has a magnetic core 110 with a plurality of channels 120. A plurality of conductive elements 130, that serve as windings on the magnetic component 100, are mounted in the channels 120. FIG. 1B illustrates how each end 135 of the conductive element 130 is bent inward against the bottom of the magnetic core 110 to form coplanar contact surfaces 136. These coplanar contact surfaces 136 permit the component 100 to be surface mountable on a substrate or other supporting surface of an electronic circuit, such as a power supply.

[0028] Turning now to FIG. 2A, illustrated is an isometric view of a frame 210 of an embodiment of an apparatus 200 for manufacturing a low profile magnetic component 100, to which is coupled a series of fixtures 220 adapted to hold magnetic cores 110. The fixtures 220 are linked together as a chain 225 with a spacing link 226, in this embodiment, between each fixture 220. A pair of sprocketed wheels 215 is configured to move the chain 225 over a surface 211 of the frame 210. The sprocketed wheels 215 are indexed so that each fixture 220 is moved into a predetermined position on the surface 211. These predetermined positions are located so that various stations (hereinafter described)coupled to the frame 210 can perform the manufacturing functions necessary to make a magnetic component 100.

[0029] Turning now to FIG. 2B, illustrated is an isometric view of an embodiment of a fixture 220 configured to hold a magnetic core 110. The fixture 220 has a receptacle 221 into which the core 110 is placed and gripping members 222 that securely hold the core 110 in position as it proceeds through the manufacturing process. The gripping members 222 can be configured to retract as the core 110 is placed in the receptacle 221 and then released to secure the core 110 when it is in the proper position.

[0030] Turning now to FIG. 2C, illustrated is an isometric view of the frame 210 with an embodiment of a loading station 230 coupled thereto. In the illustrated embodiment, after the fixture 220 is moved into position in the loading station 230, the gripping members 222 are retracted and an individual magnetic core 110 is placed in the receptacle 221 of the fixture 220. The gripping members 222 are then released to secure the core 110 in position as the magnetic component 100 is being assembled. In a particularly useful embodiment of the invention, the loading station 230 is configured to open a receiving package from a strip of such packages (not illustrated) containing magnetic cores 110, remove a core 110 and places the core 110 in the fixture 220. The strip of receiving packages, after it is emptied, can then be used for shipping packages of assembled magnetic components 100.

[0031] Turning now to FIG. 2D, illustrated an isometric view of the frame 210 with embodiments of a wire feeding and cutting station 240 and clamping station 250 coupled thereto. The wire feeding and cutting station 240 is adapted to feed and cut a wire 241 and form a conductive element 130 with a configuration for mounting on the magnetic core 110. The conductive element 130 is positioned by the wire feeding and cutting station 240 for mounting on the magnetic core 110. The fixture 220, with the conductive elements 130 positioned for mounting, is then advanced to the clamping station 250.

[0032] At the clamping station 250 the conductive elements 130 are mounted on the magnetic core 110 with each end 135 of the conductive element 130 bent inwardly against the bottom of the core 110 to form coplanar contact surfaces 136. In one embodiment, the wire feeding and cutting station 240 is adapted to form a plurality of conductive elements 130. In the embodiment illustrated, four wires 241 are being fed and cut to form four conductive elements. The invention also includes embodiments where the clamping station 250 is adapted to clamp and mount a plurality of conductive elements 130 on a magnetic core 110.

[0033] Those of ordinary skill in the pertinent art will understand that and embodiment providing for any number of wires 241 being fed, cut, formed into conductive elements 130 and clamped onto the core 110 to form magnetic components 100 is within the intended scope of the present invention. In one embodiment of the invention, a first video inspection station 260 (not visible) is coupled to the frame 210 to inspect the magnetic device 100 for proper placement of the conductive elements 130 about the core 110.

[0034] Turning now to FIG. 2E, illustrated is an isometric view of the frame 210 with an embodiment of the final clamping and fixture alignment station 250 coupled thereto. After the fixture 220 carrying the magnetic component 100 is positioned, a clamp 251 (the top portion of which is shown) completes the clamping operation on the conductive elements 130 about the core 110. The fixture 220 is also aligned so that the magnetic component 100 can be electrically tested.

[0035] Turning to FIG. 2F illustrated is an isometric view of an embodiment of an electrical test station 265. The electrical test station 265 has test probes 266 and connectors 267 that go to a testing apparatus. Of course the test station 265 is coupled to the frame 210 (not shown). When the fixture 220 is in position for the component 100 to be tested, the test probes 266 can test the conductive elements 130 for certain predetermined electrical characteristics, such as the resistance and inductance as well as current carrying capacity.

[0036] Turning now to FIG. 2G, illustrated is an isometric view of the frame 210 with embodiments of a labeling station 270 and packaging station 280 coupled thereto. In the illustrated embodiment of the invention, the labeling station 270 is configured to print and locate a label on the magnetic component 100. A useful embodiment of the invention provides for a second video inspection station 275 (not visible) to be coupled to the frame 210. The second video inspection station 275 can be configured to inspect the label for conformity to certain predetermined specifications, such as correct printing and proper placement on the body of the magnetic component 100.

[0037] A particularly beneficial aspect of the illustrated embodiment of the invention is that when the component 100 is inspected at the first video inspection station 260, tested at the electrical test station 265, and inspected again at the second video inspection station 275, an immediate rejection of a defective component 100 can be made before it is packaged for shipment. In addition, if an unacceptable number of magnetic components 100 are being rejected, an operator can intervene to make necessary adjustments and restore the apparatus 200 to normal operation.

[0038] In the illustrated embodiment of the invention, after the component 100 is labeled and inspected, the fixture 220 proceeds to a packaging station 280. The packaging station 280 removes the component 100 from the fixture 220 (utilizing well known pick-and-place technology, for example) and places it into a shipping package. As previously indicated, a particularly beneficial embodiment of the invention has a packaging station 280 adapted to package completed components 100 in the same type of packaging from which magnetic cores 110 were previously removed at the loading station 230. This reuse of packaging material represents a significant savings from a manufacturing viewpoint.

[0039] Referring now to FIG. 3, illustrated is an embodiment of a method of manufacturing 300 a magnetic component using a magnetic component manufacturing apparatus. The method commences with a start step 305. In a place magnetic core step 310, a loading station coupled to the frame of a magnetic component manufacturing apparatus is used to place a magnetic core in a fixture. After the magnetic core is placed in a fixture, in a feeding and cutting step 320, a wire is fed into a feeding and cutting station, cut to predetermined length, and formed into a conductive element having a particular configuration. The conductive element is then positioned for mounting on the magnetic core.

[0040] After the conductive element is formed and positioned for mounting, a clamping and mounting step 330 is performed to mount the conductive element on the magnetic core. In order to assure the conductive element is correctly mounted, a first video inspection step 340 is performed to inspect the conductive elements about the magnetic core for conformity with certain predetermined specifications. In a test electrical characteristics step 350, the component is tested for certain electrical characteristics, such as resistance and inductance. The component is then labeled in a labeling step 360 where the label is printed and placed on the component. In a second video inspection step 370, the label is inspected for conformity with certain specifications, such as proper placement and printing. After the component is completed and properly labeled, it is packaged in a packaging step 380. In one embodiment of the invention, the packaging step 380 includes using the same type of packaging used to receive magnetic cores for shipping completed components. The method concludes with an end step 385.

[0041] The invention includes several embodiments of methods of manufacturing a low profile magnetic component manufacturing apparatus. Sufficient detail has been set forth herein to enable one of ordinary skill in the pertinent art to understand and practice the various embodiments of such methods.

[0042] Although the present invention has been described in detail, those skilled in the art should understand that they can make various changes, substitutions and alterations herein without departing from the spirit and scope of the invention in its broadest form. 

What is claimed is:
 1. A apparatus for manufacturing a low profile magnetic component, comprising: a frame; a fixture couplable to said frame and adapted to hold a magnetic core; a loading station coupled to said frame and adapted to load said magnetic core onto said fixture; a wire feeding and cutting station coupled to said frame and adapted to feed and cut a wire to form a conductive element having a particular configuration and position said conductive element for mounting on said magnetic core; and a clamping station coupled to said frame for clamping and thereby mounting said conductive element on said magnetic core.
 2. The apparatus as recited in claim 1 further comprising a first video inspection station coupled to said frame to inspect said magnetic component for conformity with certain specifications.
 3. The apparatus as recited in claim 1 further comprising an electrical test station coupled to said frame to test certain electrical characteristics of said magnetic component.
 4. The apparatus as recited in claim 1 further comprising a labeling station coupled to said frame adapted to print and place a label on said magnetic component.
 5. The apparatus as recited in claim 4 further comprising a second video inspection station coupled to said frame to inspect said label for conformity with certain specifications.
 6. The apparatus as recited in claim 1 further comprising a packaging station coupled to said frame adapted to package said magnetic component.
 7. The apparatus as recited in claim 6 wherein said loading station is configured to remove said magnetic core from a receiving package and said packaging station is adapted to package said magnetic component in a shipping package identical to said receiving package.
 8. The apparatus as recited in claim 1 wherein said wire feeding and cutting station is adapted to form a plurality of said conductive element.
 9. The apparatus as recited in claim 8 wherein said clamping station is adapted to clamp and thereby mount said plurality on said magnetic core.
 10. A method of manufacturing a low profile magnetic component manufacturing apparatus, comprising: forming a frame; coupling a fixture to said frame, said fixture adapted to hold a magnetic core; coupling a loading station to said frame, said loading station adapted to load said magnetic core onto said fixture; coupling a wire feeding and cutting station to said frame, said wire feeding and cutting station adapted to feed and cut a wire to form a conductive element having a particular configuration and position said conductive element for mounting on said magnetic core; and coupling a clamping station to said frame, said clamping station adapted for clamping and thereby mounting said conductive element on said magnetic core.
 11. The method as recited in claim 10 further comprising coupling a first video inspection station to said frame, said first video inspection station adapted to inspect said magnetic component for conformity with certain specifications.
 12. The method as recited in claim 10 further comprising coupling an electrical test station to said frame, said electrical test station adapted to test certain electrical characteristics of said magnetic component.
 13. The method as recited in claim 10 further comprising coupling a labeling station to said frame, said labeling station adapted to print and place a label on said magnetic component.
 14. The method as recited in claim 13 further comprising coupling a second video inspection station to said frame, said second video inspection station adapted to inspect said label for conformity with certain specifications.
 15. The method as recited in claim 10 further comprising coupling a packaging station to said frame, said packaging station adapted to package said magnetic component.
 16. The method as recited in claim 15 wherein said packaging station is configured to remove said magnetic core from a receiving package and said packaging station is configured to package said magnetic component in a shipping package identical to said receiving package.
 17. The method as recited in claim 10 wherein said wire feeding and cutting station is adapted to form a plurality of said conductive element.
 18. The method as recited in claim 17 wherein said clamping station is adapted to clamp and thereby mount said plurality on said magnetic core.
 19. A method of manufacturing a magnetic component using a magnetic component manufacturing apparatus, comprising: placing a magnetic core in a fixture with a loading station coupled to a frame of a magnetic component manufacturing apparatus; feeding and cutting a wire to form a conductive element having a particular configuration and positioning said conductive element for mounting on said magnetic core with a wire feeding and cutting station coupled to said frame; and clamping and mounting said conductive element on said magnetic core with a clamping station coupled to said frame.
 20. The method as recited in claim 19 further comprising inspecting said magnetic component for conformity with certain specifications with a first video inspection station coupled to said frame.
 21. The method as recited in claim 19 further comprising testing certain electrical characteristics of said magnetic component with an electrical test station coupled to said frame.
 22. The method as recited in claim 19 further comprising printing and placing a label on said magnetic component with a labeling station coupled to said frame.
 23. The method as recited in claim 22 further comprising inspecting said label for conformity with certain specifications with a second video inspection station coupled to said frame.
 24. The method as recited in claim 19 further comprising packaging said magnetic component with a packaging station coupled to said frame.
 25. The method as recited in claim 24 further comprising configuring said loading station to remove said magnetic core from a receiving package and configuring said packaging station to package said magnetic component in a shipping package identical to said receiving package.
 26. The method as recited in claim 19 further comprising forming a plurality of said conductive element with said wire feeding and cutting station.
 27. The method as recited in claim 26 further comprising clamping and mounting said plurality on said magnetic core with said clamping station. 